Adapters with end effector position sensing and control arrangements for use in connection with electromechanical surgical instruments

ABSTRACT

An adapter for use with an electromechanical surgical instrument. The adapter includes a shaft assembly and a surgical end effector that is selectively articulatable and rotatable relative to the shaft assembly through a range of articulated and rotated positions. The adapter includes sensing and control arrangements for monitoring and maintaining the end effector in articulated and/or rotated positions.

BACKGROUND

The present invention relates to surgical instruments and, in variousarrangements, to surgical stapling and cutting instruments and staplecartridges for use therewith that are designed to staple and cut tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

Various features of the embodiments described herein, together withadvantages thereof, may be understood in accordance with the followingdescription taken in conjunction with the accompanying drawings asfollows:

FIG. 1 is a perspective view of an electromechanical surgical system;

FIG. 2 is a perspective view of a distal end of an electromechanicalsurgical instrument portion of the surgical system of FIG. 1;

FIG. 3 is an exploded assembly view of an outer shell feature and theelectromechanical surgical instrument of FIG. 2;

FIG. 4 is a rear perspective view of a portion of the electromechanicalsurgical instrument of FIG. 2;

FIG. 5 is a partial exploded assembly view of a portion of an adapterand the electromechanical surgical instrument of the surgical system ofFIG. 1;

FIG. 6 is an exploded assembly view of a portion of the adapter of FIG.5;

FIG. 7 is a cross-sectional perspective view of a portion of anarticulation assembly of an adapter;

FIG. 8 is a perspective view of the articulation assembly of FIG. 7;

FIG. 9 is another perspective view of the articulation assembly of FIG.8;

FIG. 10 is an exploded assembly view of a loading unit employed in theelectromechanical surgical system of FIG. 1;

FIG. 11 is a perspective view of an alternative adapter embodiment;

FIG. 12 is a side elevational view of a portion of a loading unit of theadapter of FIG. 11 with the jaws thereof in an open position;

FIG. 13 is another side elevational view of a portion of the loadingunit of FIG. 11 with portions thereof shown in cross-section and thejaws thereof in a closed position;

FIG. 14 is a bottom view of a portion of the loading unit of FIG. 13with portions thereof shown in cross-section;

FIG. 15 is a perspective view of a portion of the loading unit of FIG.14 with a portion of the outer tube shown in phantom lines;

FIG. 16 is a cross-sectional view of a proximal portion of anotheradapter employing various seal arrangements therein;

FIG. 17 is an end cross-sectional view of a portion of the adapter ofFIG. 16;

FIG. 18 is a side elevation al view of another adapter;

FIG. 19 is a cross-sectional view of a portion of the adapter of FIG.18;

FIG. 20 is a rear perspective view of portions of another adapter;

FIG. 21 is a cross-sectional view of another adapter;

FIG. 22 is a top view of a loading unit of an adapter with the toolassembly thereof in an unarticulated position;

FIG. 23 is another top view of the loading unit of FIG. 22 with the toolassembly in a first articulated position;

FIG. 24 is another top view of the loading unit of FIGS. 22 and 23 withthe tool assembly in a second articulated position;

FIG. 25 is a perspective view of a portion of an adapter;

FIG. 26 is a perspective view of another portion of an adapter;

FIG. 27 is a partial cross-sectional perspective view of an articulationsystem and sensor assembly embodiment of an adapter in an unarticulated(neutral) position;

FIG. 28 is another perspective view of the articulation system andsensor assembly of FIG. 27 in a first articulated position;

FIG. 29 is another perspective view of the articulation system andsensor assembly of FIGS. 27 and 28 in a second articulated position;

FIG. 30 is a partial cross-sectional view a portion of an alternativeproximal drive shaft and bearing housing of an alternative articulationsystem in an unarticulated (neutral) position;

FIG. 31 is another partial cross-sectional view the portion of analternative proximal drive shaft and bearing housing of the alternativearticulation system of FIG. 30 in an articulated position;

FIG. 32 is a partial cross-sectional view a portion of an alternativeproximal drive shaft and bearing housing of an alternative articulationsystem in an unarticulated (neutral) position;

FIG. 33 is another partial cross-sectional view the portion of analternative proximal drive shaft and bearing housing of the alternativearticulation system of FIG. 32 in an articulated position;

FIG. 34 is a partial cross-sectional perspective view of anotherarticulation system and sensor assembly embodiment of an adapter in anunarticulated (neutral) position;

FIG. 35 is a partial cross-sectional side view of the articulationsystem and sensor assembly embodiment of an adapter of FIG. 34 in theunarticulated (neutral) position;

FIG. 36 is another partial cross-sectional side view of the articulationsystem and sensor assembly embodiment of an adapter of FIGS. 34 and 35in an articulated position;

FIG. 37 is another partial cross-sectional side view of the articulationsystem and sensor assembly embodiment of an adapter of FIGS. 34-36 inanother articulated position; and

FIG. 38 is a perspective view of portions of an articulation system andsensor system and a shaft rotation system and sensor arrangement ofanother adapter.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various embodiments of the invention, in one form, and suchexemplifications are not to be construed as limiting the scope of theinvention in any manner.

DETAILED DESCRIPTION

Applicant of the present application owns the following U.S. patentapplications that were filed on Dec. 15, 2017 and which are each hereinincorporated by reference in their respective entireties:

-   -   U.S. patent application Ser. No. 15/843,485, entitled SEALED        ADAPTERS FOR USE WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS,        now U.S. Patent Application Publication No. 2019/0183492;    -   U.S. patent application Ser. No. 15/843,518, entitled END        EFFECTORS WITH POSITIVE JAW OPENING FEATURES FOR USE WITH        ADAPTERS FOR ELECTROMECHANICAL SURGICAL INSTRUMENTS, now U.S.        Patent Application Publication No. 2019/0183496;    -   U.S. patent application Ser. No. 15/843,535, entitled SURGICAL        END EFFECTORS WITH CLAMPING ASSEMBLIES CONFIGURED TO INCREASE        JAW APERTURE RANGES, now U.S. Patent Application Publication No.        2019/0183498;    -   U.S. patent application Ser. No. 15/843,558, entitled SURGICAL        END EFFECTORS WITH PIVOTAL JAWS CONFIGURED TO TOUCH AT THEIR        RESPECTIVE DISTAL ENDS WHEN FULLY CLOSED, now U.S. Patent        Application Publication No. 2019/0183499;    -   U.S. patent application Ser. No. 15/843,528, entitled SURGICAL        END EFFECTORS WITH JAW STIFFENER ARRANGEMENTS CONFIGURED TO        PERMIT MONITORING OF FIRING MEMBER, now U.S. Patent Application        Publication No. 2019/0183497;    -   U.S. patent application Ser. No. 15/843,556, entitled DYNAMIC        CLAMPING ASSEMBLIES WITH IMPROVED WEAR CHARACTERISTICS FOR USE        IN CONNECTION WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS, now        U.S. Patent Application Publication No. 2019/0183490;    -   U.S. patent application Ser. No. 15/843,514, entitled ADAPTERS        WITH FIRING STROKE SENSING ARRANGEMENTS FOR USE IN CONNECTION        WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS, now U.S. Patent        Application Publication No. 2019/0183495;    -   U.S. patent application Ser. No. 15/843,501, entitled ADAPTERS        WITH CONTROL SYSTEMS FOR CONTROLLING MULTIPLE MOTORS OF AN        ELECTROMECHANICAL SURGICAL INSTRUMENT, now U.S. Patent        Application Publication No. 2019/0183493;    -   U.S. patent application Ser. No. 15/843,508, entitled HANDHELD        ELECTROMECHANICAL SURGICAL INSTRUMENTS WITH IMPROVED MOTOR        CONTROL ARRANGEMENTS FOR POSITIONING COMPONENTS OF AN ADAPTER        COUPLED THERETO, now U.S. Patent Application Publication No.        2019/0183494;    -   U.S. patent application Ser. No. 15/843,682, entitled SYSTEMS        AND METHODS OF CONTROLLING A CLAMPING MEMBER FIRING RATE OF A        SURGICAL INSTRUMENT, now U.S. Patent Application Publication No.        2019/0183501;    -   U.S. patent application Ser. No. 15/843,689, entitled SYSTEMS        AND METHODS OF CONTROLLING A CLAMPING MEMBER, now U.S. Patent        Application Publication No. 2019/0183502; and    -   U.S. patent application Ser. No. 15/843,704, entitled METHODS OF        OPERATING SURGICAL END EFFECTORS, now U.S. Patent Application        Publication No. 2019/0183503.

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof the embodiments as described in the specification and illustrated inthe accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, thereader will readily appreciate that the various methods and devicesdisclosed herein can be used in numerous surgical procedures andapplications including, for example, in connection with open surgicalprocedures. As the present Detailed Description proceeds, the readerwill further appreciate that the various instruments disclosed hereincan be inserted into a body in any way, such as through a naturalorifice, through an incision or puncture hole formed in tissue, etc. Theworking portions or end effector portions of the instruments can beinserted directly into a patient's body or can be inserted through anaccess device that has a working channel through which the end effectorand elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effectorextending from the shaft. The end effector comprises a first jaw and asecond jaw. The first jaw comprises a staple cartridge. The staplecartridge is insertable into and removable from the first jaw; however,other embodiments are envisioned in which a staple cartridge is notremovable from, or at least readily replaceable from, the first jaw. Thesecond jaw comprises an anvil configured to deform staples ejected fromthe staple cartridge. The second jaw is pivotable relative to the firstjaw about a closure axis; however, other embodiments are envisioned inwhich the first jaw is pivotable relative to the second jaw. Thesurgical stapling system further comprises an articulation jointconfigured to permit the end effector to be rotated, or articulated,relative to the shaft. The end effector is rotatable about anarticulation axis extending through the articulation joint. Otherembodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge bodyincludes a proximal end, a distal end, and a deck extending between theproximal end and the distal end. In use, the staple cartridge ispositioned on a first side of the tissue to be stapled and the anvil ispositioned on a second side of the tissue. The anvil is moved toward thestaple cartridge to compress and clamp the tissue against the deck.Thereafter, staples removably stored in the cartridge body can bedeployed into the tissue. The cartridge body includes staple cavitiesdefined therein wherein staples are removably stored in the staplecavities. The staple cavities are arranged in six longitudinal rows.Three rows of staple cavities are positioned on a first side of alongitudinal slot and three rows of staple cavities are positioned on asecond side of the longitudinal slot. Other arrangements of staplecavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. Thedrivers are movable between a first, or unfired position, and a second,or fired, position to eject the staples from the staple cavities. Thedrivers are retained in the cartridge body by a retainer which extendsaround the bottom of the cartridge body and includes resilient membersconfigured to grip the cartridge body and hold the retainer to thecartridge body. The drivers are movable between their unfired positionsand their fired positions by a sled. The sled is movable between aproximal position adjacent the proximal end and a distal positionadjacent the distal end. The sled comprises a plurality of rampedsurfaces configured to slide under the drivers and lift the drivers, andthe staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. Thefiring member is configured to contact the sled and push the sled towardthe distal end. The longitudinal slot defined in the cartridge body isconfigured to receive the firing member. The anvil also includes a slotconfigured to receive the firing member. The firing member furthercomprises a first cam which engages the first jaw and a second cam whichengages the second jaw. As the firing member is advanced distally, thefirst cam and the second cam can control the distance, or tissue gap,between the deck of the staple cartridge and the anvil. The firingmember also comprises a knife configured to incise the tissue capturedintermediate the staple cartridge and the anvil. It is desirable for theknife to be positioned at least partially proximal to the rampedsurfaces such that the staples are ejected ahead of the knife.

FIG. 1 depicts a motor-driven (electromechanical) surgical system 1 thatmay be used to perform a variety of different surgical procedures. Ascan be seen in that Figure, one example of the surgical system 1includes a powered handheld electromechanical surgical instrument 100that is configured for selective attachment thereto of a plurality ofdifferent surgical tool implements (referred to herein as “adapters”)that are each configured for actuation and manipulation by the poweredhandheld electromechanical surgical instrument. As illustrated in FIG.1, the handheld surgical instrument 100 is configured for selectiveconnection with an adapter 200, and, in turn, adapter 200 is configuredfor selective connection with end effectors that comprise a single useloading unit (“SULU”) or a disposable loading unit (“DLU”) or a multipleuse loading unit (“MULU”). In another surgical system embodiment,various forms of adapter 200 may also be effectively employed with atool drive assembly of a robotically controlled or automated surgicalsystem. For example, the surgical tool assemblies disclosed herein maybe employed with various robotic systems, instruments, components andmethods such as, but not limited to, those disclosed in U.S. Pat. No.9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLEDEPLOYMENT ARRANGEMENTS, which is hereby incorporated by referenceherein in its entirety.

As illustrated in FIGS. 1 and 2, surgical instrument 100 includes apower-pack 101 and an outer shell housing 10 that is configured toselectively receive and substantially encase the power-pack 101. Thepower pack 101 may also be referred to herein as handle assembly 101.One form of surgical instrument 100, for example, is disclosed inInternational Publication No. WO 2016/057225 A1, InternationalApplication No. PCT/US2015/051837, entitled HANDHELD ELECTROMECHANICALSURGICAL SYSTEM, the entire disclosure of which is hereby incorporatedby reference herein. Various features of surgical instrument 100 willnot be disclosed herein beyond what is necessary to understand thevarious features of the inventions disclosed herein with it beingunderstood that further details may be gleaned from reference to WO2016/057225 A1 and other references incorporated by reference herein.

As illustrated in FIG. 3, outer shell housing 10 includes a distalhalf-section 10 a and a proximal half-section 10 b that is pivotablyconnected to distal half-section 10 a by a hinge 16 located along anupper edge of distal half-section 10 a and proximal half-section 10 b.When joined, distal and proximal half-sections 10 a, 10 b define a shellcavity 10 c therein in which the power-pack 101 is selectively situated.Each of distal and proximal half-sections 10 a, 10 b includes arespective upper shell portion 12 a, 12 b, and a respective lower shellportion 14 a, 14 b. Lower shell portions 14 a, 14 b define a snapclosure feature 18 for selectively securing the lower shell portions 14a, 14 b to one another and for maintaining shell housing 10 in a closedcondition. Distal half-section 10 a of shell housing 10 defines aconnecting portion 20 that is configured to accept a corresponding drivecoupling assembly 210 of adapter 200 (see FIG. 5). Specifically, distalhalf-section 10 a of shell housing 10 has a recess that receives aportion of drive coupling assembly 210 of adapter 200 when adapter 200is mated to surgical instrument 100.

Connecting portion 20 of distal half-section 10 a defines a pair ofaxially extending guide rails 21 a, 21 b that project radially inwardfrom inner side surfaces thereof as shown in FIG. 5. Guide rails 21 a,21 b assist in rotationally orienting adapter 200 relative to surgicalinstrument 100 when adapter 200 is mated to surgical instrument 100.Connecting portion 20 of distal half-section 10 a defines threeapertures 22 a, 22 b, 22 c that are formed in a distally facing surfacethereof and which are arranged in a common plane or line with oneanother. Connecting portion 20 of distal half-section 10 a also definesan elongate slot 24 also formed in the distally facing surface thereof.Connecting portion 20 of distal half-section 10 a further defines afemale connecting feature 26 (see FIG. 2) formed in a surface thereof.Female connecting feature 26 selectively engages with a male connectingfeature of adapter 200.

Distal half-section 10 a of shell housing 10 supports a distal facingtoggle control button 30. The toggle control button 30 is capable ofbeing actuated in a left, right, up and down direction upon applicationof a corresponding force thereto or a depressive force thereto. Distalhalf-section 10 a of shell housing 10 supports a right-side pair ofcontrol buttons 32 a, 32 b (see FIG. 3); and a left-side pair of controlbutton 34 a, 34 b (see FIG. 2). The right-side control buttons 32 a, 32b and the left-side control buttons 34 a, 34 b are capable of beingactuated upon application of a corresponding force thereto or adepressive force thereto. Proximal half-section 10 b of shell housing 10supports a right-side control button 36 a (see FIG. 3) and a left-sidecontrol button 36 b (see FIG. 2). Right-side control button 36 a andleft-side control button 36 b are capable of being actuated uponapplication of a corresponding force thereto or a depressive forcethereto.

Shell housing 10 includes a sterile barrier plate assembly 60selectively supported in distal half-section 10 a. Specifically, thesterile barrier plate assembly 60 is disposed behind connecting portion20 of distal half-section 10 a and within shell cavity 10 c of shellhousing 10. The plate assembly 60 includes a plate 62 rotatablysupporting three coupling shafts 64 a, 64 b, 64 c (see FIGS. 3 and 5).Each coupling shaft 64 a, 64 b, 64 c extends from opposed sides of plate62 and has a tri-lobe transverse cross-sectional profile. Each couplingshaft 64 a, 64 b, 64 c extends through the respective apertures 22 a, 22b, 22 c of connecting portion 20 of distal half-section 10 a when thesterile barrier plate assembly 60 is disposed within shell cavity 10 cof shell housing 10. The plate assembly 60 further includes anelectrical pass-through connector 66 supported on plate 62. Pass-throughconnector 66 extends from opposed sides of plate 62. Pass-throughconnector 66 defines a plurality of contact paths each including anelectrical conduit for extending an electrical connection across plate62. When the plate assembly 60 is disposed within shell cavity 10 c ofshell housing 10, distal ends of coupling shaft 64 a, 64 b, 64 c and adistal end of pass-through connector 66 are disposed or situated withinconnecting portion 20 of distal half-section 10 a of shell housing 10,and are configured to electrically and/or mechanically engage respectivecorresponding features of adapter 200.

Referring to FIGS. 3 and 4, the power-pack or the handle assembly 101includes an inner handle housing 110 having a lower housing portion 104and an upper housing portion 108 extending from and/or supported onlower housing portion 104. Lower housing portion 104 and upper housingportion 108 are separated into a distal half section 110 a and aproximal half-section 110 b connectable to distal half-section 110 a bya plurality of fasteners. When joined, distal and proximal half-sections110 a, 110 b define the inner handle housing 110 having an inner housingcavity 110 c therein in which a power-pack core assembly 106 issituated. Power-pack core assembly 106 is configured to control thevarious operations of surgical instrument 100.

Distal half-section 110 a of inner handle housing 110 supports a distaltoggle control interface 130 that is in operative registration with thedistal toggle control button 30 of shell housing 10. In use, when thepower-pack 101 is disposed within shell housing 10, actuation of thetoggle control button 30 exerts a force on toggle control interface 130.Distal half-section 110 a of inner handle housing 110 also supports aright-side pair of control interfaces (not shown), and a left-side pairof control interfaces 132 a, 132 b. In use, when the power-pack 101 isdisposed within shell housing 10, actuation of one of the right-sidepair of control buttons or the left-side pair of control button ofdistal half-section 10 a of shell housing 10 exerts a force on arespective one of the right-side pair of control interfaces 132 a, 132 bor the left-side pair of control interfaces 132 a, 132 b of distalhalf-section 110 a of inner handle housing 110.

With reference to FIGS. 1-5, inner handle housing 110 provides a housingin which power-pack core assembly 106 is situated. Power-pack coreassembly 106 includes a battery circuit 140, a controller circuit board142 and a rechargeable battery 144 configured to supply power to any ofthe electrical components of surgical instrument 100. Controller circuitboard 142 includes a motor controller circuit board 142 a, a maincontroller circuit board 142 b, and a first ribbon cable 142 cinterconnecting motor controller circuit board 142 a and main controllercircuit board 142 b. Power-pack core assembly 106 further includes adisplay screen 146 supported on main controller circuit board 142 b.Display screen 146 is visible through a clear or transparent window 110d (see FIG. 3) provided in proximal half-section 110 b of inner handlehousing 110. It is contemplated that at least a portion of inner handlehousing 110 may be fabricated from a transparent rigid plastic or thelike. It is further contemplated that shell housing 10 may eitherinclude a window formed therein (in visual registration with displayscreen 146 and with window 110 d of proximal half-section 110 b of innerhandle housing 110, and/or shell housing 10 may be fabricated from atransparent rigid plastic or the like.

Power-pack core assembly 106 further includes a first motor 152, asecond motor 154, and a third motor 156 that are supported by motorbracket 148 and are each electrically connected to controller circuitboard 142 and battery 144. Motors 152, 154, 156 are disposed betweenmotor controller circuit board 142 a and main controller circuit board142 b. Each motor 152, 154, 156 includes a respective motor shaft 152 a,154 a, 156 a extending therefrom. Each motor shaft 152 a, 154 a, 156 ahas a tri-lobe transverse cross-sectional profile for transmittingrotative forces or torque. Each motor 152, 154, 156 is controlled by arespective motor controller. Rotation of motor shafts 152 a, 154 a, 156a by respective motors 152, 154, 156 function to drive shafts and/orgear components of adapter 200 in order to perform the variousoperations of surgical instrument 100. In particular, motors 152, 154,156 of power-pack core assembly 106 are configured to drive shaftsand/or gear components of adapter 200.

As illustrated in FIGS. 1 and 5, surgical instrument 100 is configuredfor selective connection with adapter 200, and, in turn, adapter 200 isconfigured for selective connection with end effector 500. Adapter 200includes an outer knob housing 202 and an outer tube 206 that extendsfrom a distal end of knob housing 202. Knob housing 202 and outer tube206 are configured and dimensioned to house the components of adapterassembly 200. Outer tube 206 is dimensioned for endoscopic insertion, inparticular, that outer tube is passable through a typical trocar port,cannula or the like. Knob housing 202 is dimensioned to not enter thetrocar port, cannula of the like. Knob housing 202 is configured andadapted to connect to connecting portion 20 of the outer shell housing10 of surgical instrument 100.

Adapter 200 is configured to convert a rotation of either of first orsecond coupling shafts 64 a, 64 b of surgical instrument 100 into axialtranslation useful for operating a drive assembly 540 and anarticulation link 560 of end effector 500, as illustrated in FIG. 10 andas will be described in greater detail below. As illustrated in FIG. 6,adapter 200 includes the proximal inner housing assembly 204 thatrotatably supports a first rotatable proximal drive shaft 212, a secondrotatable proximal drive shaft 214, and a third rotatable proximal driveshaft 216 therein. Each proximal drive shaft 212, 214, 216 functions asa rotation receiving member to receive rotational forces from respectivecoupling shafts 64 a, 64 b and 64 c of surgical instrument 100. Inaddition, the drive coupling assembly 210 of adapter 200 is alsoconfigured to rotatably support first, second and third connectorsleeves 218, 220 and 222, respectively, arranged in a common plane orline with one another. Each connector sleeve 218, 220, 222 is configuredto mate with respective first, second and third coupling shafts 64 a, 64b, 64 c of surgical instrument 100, as described above. Each connectorsleeves 218, 222, 220 is further configured to mate with a proximal endof respective first, second, and third proximal drive shafts 212, 214,216 of adapter 200.

Drive coupling assembly 210 of adapter 200 also includes a first, asecond, and a third biasing member 224, 226, and 228 disposed distallyof respective first, second, and third connector sleeves 218, 220, 222.Each biasing members 224, 226, and 228 is disposed about respectivefirst, second, and third rotatable proximal drive shaft 212, 214, and216. Biasing members 224, 226, and 228 act on respective connectorsleeves 218, 222, and 220 to help maintain connector sleeves 218, 222.and 220 engaged with the distal end of respective coupling shafts 64 a,64 b, and 64 c of surgical instrument 100 when adapter 200 is connectedto surgical instrument 100.

Also in the illustrated arrangement, adapter 200 includes first, second,and third drive converting assemblies 240, 250, 260, respectively, thatare each disposed within inner housing assembly 204 and outer tube 206.Each drive converting assembly 240, 250, 260 is configured and adaptedto transmit or convert a rotation of a first, second, and third couplingshafts 64 a, 64 b, and 64 c of surgical instrument 100 into axialtranslation of an articulation driver or bar 258 of adapter 200, toeffectuate articulation of end effector 500; a rotation of a ring gear266 of adapter 200, to effectuate rotation of adapter 200; or axialtranslation of a distal drive member 248 of adapter 200 to effectuateclosing, opening, and firing of end effector 500.

Still referring to FIG. 6, first force/rotation transmitting/convertingassembly 240 includes first rotatable proximal drive shaft 212, which,as described above, is rotatably supported within inner housing assembly204. First rotatable proximal drive shaft 212 includes a non-circular orshaped proximal end portion configured for connection with firstconnector sleeve 218 which is connected to respective first couplingshaft 64 a of surgical instrument 100. First rotatable proximal driveshaft 212 includes a threaded distal end portion 212 b. Firstforce/rotation transmitting/converting assembly 240 further includes adrive coupling nut 244 that threadably engages the threaded distal endportion 212 b of first rotatable proximal drive shaft 212, and which isslidably disposed within outer tube 206. Drive coupling nut 244 isslidably keyed within proximal core tube portion of outer tube 206 so asto be prevented from rotation as first rotatable proximal drive shaft212 is rotated. In this manner, as the first rotatable proximal driveshaft 212 is rotated, drive coupling nut 244 is translated alongthreaded distal end portion 212 b of first rotatable proximal driveshaft 212 and, in turn, through and/or along outer tube 206.

First force/rotation transmitting/converting assembly 240 furtherincludes a distal drive member 248 that is mechanically engaged withdrive coupling nut 244, such that axial movement of drive coupling nut244 results in a corresponding amount of axial movement of distal drivemember 248. The distal end portion of distal drive member 248 supports aconnection member 247 configured and dimensioned for selectiveengagement with an engagement member 546 of a drive assembly 540 of endeffector 500 (FIG. 10). Drive coupling nut 244 and/or distal drivemember 248 function as a force transmitting member to components of endeffector 500. In operation, as first rotatable proximal drive shaft 212is rotated, as a result of the rotation of first coupling shaft 64 a ofsurgical instrument 100, drive coupling nut 244 is translated axiallyalong first rotatable proximal drive shaft 212. As drive coupling nut244 is translated axially along first rotatable proximal drive shaft212, distal drive member 248 is translated axially relative to outertube 206. As distal drive member 248 is translated axially, withconnection member 247 connected thereto and engaged with a hollow drivemember 548 attached to drive assembly 540 of end effector 500 (FIG. 10),distal drive member 248 causes concomitant axial translation of driveassembly 540 of end effector 500 to effectuate a closure of a toolassembly portion 600 of the end effector 500 and a firing of variouscomponents within the tool assembly.

Still referring to FIG. 6, second drive converting assembly 250 ofadapter 200 includes second proximal drive shaft 214 that is rotatablysupported within inner housing assembly 204. Second rotatable proximaldrive shaft 214 includes a non-circular or shaped proximal end portionconfigured for connection with second coupling shaft 64 c of surgicalinstrument 100. Second rotatable proximal drive shaft 214 furtherincludes a threaded distal end portion 214 a configured to threadablyengage an articulation bearing housing 253 of an articulation bearingassembly 252. Referring to FIGS. 6-9, the articulation bearing housing253 supports an articulation bearing 255 that has an inner race 257 thatis independently rotatable relative to an outer race 259. Articulationbearing housing 253 has a non-circular outer profile, for exampletear-dropped shaped, that is slidably and non-rotatably disposed withina complementary bore (not shown) of inner housing hub 204 a. Seconddrive converting assembly 250 of adapter 200 further includesarticulation bar 258 that has a proximal portion that is secured toinner race 257 of articulation bearing 255. A distal portion ofarticulation bar 258 includes a slot 258 a therein, which is configuredto accept a hook 562 the articulation link 560 (FIG. 10) of end effector500. Articulation bar 258 functions as a force transmitting member tocomponents of end effector 500. In the illustrated arrangement and asfurther discussed in WO 2016/057225 A1, articulation bearing assembly252 is both rotatable and longitudinally translatable and is configuredto permit free, unimpeded rotational movement of end effector 500 whenits first and second jaw members 610, 700 are in an approximatedposition and/or when jaw members 610, 700 are articulated.

In operation, as second proximal drive shaft 214 is rotated, thearticulation bearing assembly 252 is axially translated along threadeddistal end portion 214 a of second proximal drive shaft 214, which inturn, causes articulation bar 258 to be axially translated relative toouter tube 206. As articulation bar 258 is translated axially,articulation bar 258, being coupled to articulation link 560 of endeffector 500, causes concomitant axial translation of articulation link560 of end effector 500 to effectuate an articulation of tool assembly600. Articulation bar 258 is secured to inner race 257 of articulationbearing 253 and is thus free to rotate about the longitudinal axisrelative to outer race 259 of articulation bearing 253.

As illustrated in FIG. 6, adapter 200 includes a third drive convertingassembly 260 that is supported in inner housing assembly 204. Thirddrive converting assembly 260 includes rotation ring gear 266 that isfixedly supported in and connected to outer knob housing 202. Ring gear266 defines an internal array of gear teeth 266 a and includes a pair ofdiametrically opposed, radially extending protrusions 266 b. Protrusions266 b are configured to be disposed within recesses defined in outerknob housing 202, such that rotation of ring gear 266 results inrotation of outer knob housing 202, and vice a versa. Third driveconverting assembly 260 further includes third rotatable proximal driveshaft 216 which, as described above, is rotatably supported within innerhousing assembly 204. Third rotatable proximal drive shaft 216 includesa non-circular or shaped proximal end portion that is configured forconnection with third connector 220. Third rotatable proximal driveshaft 216 includes a spur gear 216 keyed to a distal end thereof. Areversing spur gear 264 inter-engages spur gear 216 a of third rotatableproximal drive shaft 216 to gear teeth 266 a of ring gear 266. Inoperation, as third rotatable proximal drive shaft 216 is rotated, dueto a rotation of the third coupling shaft 64 b of surgical instrument100, spur gear 216 a of third rotatable proximal drive shaft 216 engagesreversing gear 264 causing reversing gear 264 to rotate. As reversinggear 264 rotates, ring gear 266 also rotates thereby causing outer knobhousing 202 to rotate. Rotation of the outer knob housing 202 causes theouter tube 206 to rotate about longitudinal axis of adapter 200. Asouter tube 206 is rotated, end effector 500 that is connected to adistal end portion of adapter 200, is also rotated about a longitudinalaxis of adapter 200.

Adapter 200 further includes an attachment/detachment button 272 (FIG.5) that is supported on a stem 273 (FIG. 6) that projects from drivecoupling assembly 210 of adapter 200. The attachment/detachment button272 is biased by a biasing member (not shown) that is disposed within oraround stem 273, to an un-actuated condition. Button 272 includes a lipor ledge that is configured to snap behind a corresponding lip or ledgeof connecting portion 20 of the surgical instrument 100. As alsodiscussed in WO 2016/057225 A1, the adapter 200 may further include alock mechanism 280 for fixing the axial position of distal drive member248. As can be seen in FIG. 21, for example, lock mechanism 280 includesa button 282 that is slidably supported on outer knob housing 202. Lockbutton 282 is connected to an actuation bar (not shown) that extendslongitudinally through outer tube 206. Actuation bar moves upon amovement of lock button 282. In operation, in order to lock the positionand/or orientation of distal drive member 248, a user moves lock button282 from a distal position to a proximal position, thereby causing thelock out (not shown) to move proximally such that a distal face of thelock out moves out of contact with camming member 288, which causescamming member 288 to cam into recess 249 of distal drive member 248. Inthis manner, distal drive member 248 is prevented from distal and/orproximal movement. When lock button 282 is moved from the proximalposition to the distal position, the distal end of actuation bar movesdistally into the lock out (not shown), against the bias of a biasingmember (not shown), to force camming member 288 out of recess 249,thereby allowing unimpeded axial translation and radial movement ofdistal drive member 248.

Returning again to FIG. 6, adapter 200 includes an electrical assembly290 supported on and in outer knob housing 202 and inner housingassembly 204. Electrical assembly 290 includes a plurality of electricalcontact blades 292, supported on a circuit board 294, for electricalconnection to pass-through connector of plate assembly of shell housing10 of surgical instrument 100. Electrical assembly 290 serves to allowfor calibration and communication information (i.e., life-cycleinformation, system information, force information) to pass to thecircuit board of surgical instrument 100 via an electrical receptacleportion of the power-pack core assembly 106 of surgical instrument 100.Electrical assembly 290 further includes a strain gauge 296 that iselectrically connected to circuit board 294. Strain gauge 296 is mountedwithin the inner housing assembly 204 to restrict rotation of the straingauge 296 relative thereto. First rotatable proximal drive shaft 212extends through strain gauge 296 to enable the strain gauge 296 toprovide a closed-loop feedback to a firing/clamping load exhibited byfirst rotatable proximal drive shaft 212. Electrical assembly 290 alsoincludes a slip ring 298 that is non-rotatably and slidably disposedalong drive coupling nut 244 of outer tube 206. Slip ring 298 is inelectrical connection with circuit board 294 and serves to permitrotation of first rotatable proximal drive shaft 212 and axialtranslation of drive coupling nut 244 while still maintaining electricalcontact of slip ring 298 with at least another electrical componentwithin adapter 200, and while permitting the other electrical componentsto rotate about first rotatable proximal drive shaft 212 and drivecoupling nut 244.

Still referring to FIG. 6, inner housing assembly 204 includes a hub 205that has a distally oriented annular wall 207 that defines asubstantially circular outer profile. Hub 205 includes a substantiallytear-drop shaped inner recess or bore that is shaped and dimensioned toslidably receive articulation bearing assembly 252 therewithin. Innerhousing assembly 204 further includes a ring plate 254 that is securedto a distal face of distally oriented annular wall 207 of hub 204 a.Ring plate 254 defines an aperture 254 a therethrough that is sized andformed therein so as to be aligned with second proximal drive shaft 214and to rotatably receive a distal tip thereof. In this manner, thedistal tip of the second proximal drive shaft 214 is supported andprevented from moving radially away from a longitudinal rotational axisof second proximal drive shaft 214 as second proximal drive shaft 214 isrotated to axially translate articulation bearing assembly 252.

Turning next to FIG. 10, in one example, the end effector 500 may beconfigured for a single use (“disposable loading unit—DLU”) and besimilar to those DLU's disclosed in U.S. Patent Application PublicationNo. 2010/0301097, entitled LOADING UNIT HAVING DRIVE ASSEMBLY LOCKINGMECHANISM, now U.S. Pat. No. 9,795,384, U.S. Patent ApplicationPublication No. 2012/0217284, entitled LOCKING MECHANISM FOR USE WITHLOADING UNITS, now U.S. Pat. No. 8,292,158, and U.S. Patent ApplicationPublication No. 2015/0374371, entitled ADAPTER ASSEMBLIES FORINTERCONNECTING SURGICAL LOADING UNITS AND HANDLE ASSEMBLIES, the entiredisclosures of each such references being hereby incorporated byreference herein. It is also contemplated that the end effector 500 maybe configured for multiple uses (MULU) such as those end effectorsdisclosed in U.S. Patent Application Publication No. 2017/0095250,entitled MULTI-USE LOADING UNIT, the entire disclosure of which ishereby incorporated by reference herein.

The depicted surgical instrument 100 fires staples, but it may beadapted to fire any other suitable fastener such as clips and two-partfasteners. In the illustrated arrangement, the end effector 500comprises a loading unit 510. The loading unit 510 comprises a proximalbody portion 520 and a tool assembly 600. Tool assembly 600 includes apair of jaw members including a first jaw member 610 that comprises ananvil assembly 612 and a second jaw member 700 that comprises acartridge assembly 701. One jaw member is pivotal in relation to theother to enable the clamping of tissue between the jaw members. Thecartridge assembly 701 is movable in relation to anvil assembly 612 andis movable between an open or unclamped position and a closed orapproximated position. However, the anvil assembly 612, or both thecartridge assembly 701 and the anvil assembly 612, can be movable.

The cartridge assembly 701 has a cartridge body 702 and in someinstances a support plate 710 that are attached to a channel 720 by asnap-fit connection, a detent, latch, or by another type of connection.The cartridge assembly 701 includes fasteners or staples 704 that aremovably supported in a plurality of laterally spaced staple retentionslots 706, which are configured as openings in a tissue contactingsurface 708. Each slot 706 is configured to receive a fastener or stapletherein. Cartridge body 702 also defines a plurality of cam wedge slotswhich accommodate staple pushers 709 and which are open on the bottom(i.e., away from tissue-contacting surface) to allow an actuation sled712 to pass longitudinally therethrough. The cartridge assembly 701 isremovable from channel 720 after the staples have been fired fromcartridge body 702. Another removable cartridge assembly is capable ofbeing loaded onto channel 720, such that surgical instrument 100 can beactuated again to fire additional fasteners or staples. Further detailsconcerning the cartridge assembly may be found, for example, in U.S.Patent Application Publication No. 2017/0095250 as well as various otherreferences that have been incorporated by reference herein.

Cartridge assembly 701 is pivotal in relation to anvil assembly 612 andis movable between an open or unclamped position and a closed or clampedposition for insertion through a cannula of a trocar. Proximal bodyportion 520 includes at least a drive assembly 540 and an articulationlink 560. In one arrangement, drive assembly 540 includes a flexibledrive beam 542 that has a distal end 544 and a proximal engagementsection 546. A proximal end of the engagement section 546 includesdiametrically opposed inwardly extending fingers 547 that engage ahollow drive member 548 to fixedly secure drive member 548 to theproximal end of beam 542. Drive member 548 defines a proximal portholewhich receives connection member 247 of drive tube 246 of first driveconverting assembly 240 of adapter 200 when the end effector 500 isattached to the distal end of the adapter 200.

End effector 500 further includes a housing assembly 530 that comprisesan outer housing 532 and an inner housing 534 that is disposed withinouter housing 532. First and second lugs 536 are each disposed on anouter surface of a proximal end 533 of outer housing 532 and areconfigured to operably engage the distal end of the adapter 200 asdiscussed in further detail in WO 2016/057225 A1.

With reference to FIG. 10, for example, anvil assembly 612 includes ananvil cover 630 and an anvil plate 620, which includes a plurality ofstaple forming depressions. Anvil plate 620 is secured to an undersideof anvil cover 630. When tool assembly 600 is in the approximatedposition, staple forming depressions are positioned in juxtaposedalignment with staple receiving slots of the cartridge assembly 701.

The tool assembly 600 includes a mounting assembly 800 that comprises anupper mounting portion 810 and a lower mounting portion 812. A mountingtail 632 protrudes proximally from a proximal end 631 of the anvil cover630. A centrally-located pivot member 814 extends from each upper andlower mounting portions 810 and 812 through openings 822 that are formedin coupling members 820. In at least one arrangement, the pivot member814 of the upper mounting portion 810 also extends through an opening634 in the mounting tail 632 as well. Coupling members 820 each includean interlocking proximal portion 824 that is configured to be receivedin corresponding grooves formed in distal ends of the outer housing 532and inner housing 534. Proximal body portion 520 of end effector 500includes articulation link 560 that has a hooked proximal end 562. Thearticulation link 560 is dimensioned to be slidably positioned within aslot in the inner housing. A pair of H-block assemblies 830 arepositioned adjacent the distal end of the outer housing 532 and adjacentthe distal end 544 of axial drive assembly 540 to prevent outwardbuckling and bulging of the flexible drive beam 542 during articulationand firing of surgical stapling apparatus 10. Each H-block assembly 830includes a flexible body 832 which includes a proximal end fixedlysecured to the distal end of the outer housing 532 and a distal end thatis fixedly secured to mounting assembly 800. In one arrangement, adistal end 564 of the articulation link is pivotally pinned to the rightH block assembly 830. Axial movement of the articulation link 560 willcause the tool assembly to articulate relative to the body portion 520.

FIGS. 11-15 illustrate an adapter 200′ that is substantially identicalto adapter 200 described above, except for the differences noted below.As can be seen in FIG. 11, the adapter 200′ includes an outer tube 206that has a proximal end portion 910 that has a first diameter “FD” andis mounted within the outer knob housing 202. The proximal end portion910 may be coupled to the inner housing assembly 204 or otherwisesupported therein in the manners discussed in further detail in WO2016/057225 A1 for example. The proximal end portion 910 extendsproximally from a central tube portion 912 that has a second diameter“SD”. In the illustrated embodiment, an end effector 500 is coupled to adistal end 914 of a shaft assembly 203 or outer tube 206. The outer tube206 defines a longitudinal axis LA that extends between the proximal endportion 910 and the distal end 914 as can be seen in FIG. 11. As can beseen in FIGS. 10 and 11, an outer sleeve 570 of the proximal bodyportion 520 of the end effector 500 has a distal end portion 572 and aproximal end portion 574. The proximal end portion 574 has a diameterSD′ that is approximately equal to the second diameter SD of the centraltube portion 912. The distal end portion 572 has a third diameter “TD”.In one arrangement, FD and TD are approximately equal and greater thanSD. Other arrangements are contemplated wherein FD and TD are not equal,but each are greater than SD. However, it is preferable that for mostcases FD and TD are dimensioned for endoscopic insertion through atypical trocar port, cannula or the like. In at least one arrangement(FIG. 11), the outer sleeve 570 is formed with a flat or scalloped side576 to facilitate improved access within the patient while effectivelyaccommodating the various drive and articulation components of theadapter 200′. In addition, by providing the central tube portion 912with a reduced diameter may afford the adapter 200′ with improvedthoracic in-between rib access.

In at least one arrangement, channel 720, which may be machined or madeof sheet metal, includes a pair of proximal holes 722 (FIG. 10) that areconfigured to align with a pair of corresponding holes 636 in the anvilcover 630 to receive corresponding pins or bosses 638 (FIG. 12) tofacilitate a pivotal relationship between anvil assembly 612 andcartridge assembly 701. In the illustrated example, a dynamic clampingassembly 550 is attached to or formed at the distal end 544 of theflexible drive beam 542. The dynamic clamping assembly 550 includes avertical body portion 552 that has a tissue cutting surface 554 formedthereon or attached thereto. See FIG. 10, for example. An anvilengagement feature 556 is formed on one end of the body portion 552 andcomprises an anvil engagement tab 557 that protrudes from each lateralside of the body portion 552. Similarly, a channel engagement feature558 is formed on the other end of the of the body portion 552 andcomprises a channel engagement tab 559 that protrudes from each lateralside of the body portion 552. See FIG. 15.

As indicated above, the anvil assembly 612 includes an anvil plate 620.The anvil plate 620 includes an elongate slot 622 that is configured toaccommodate the body portion 552 of the dynamic clamping assembly 550 asthe dynamic clamping assembly 550 is axially advanced during the firingprocess. The elongate slot 622 is defined between two anvil plate ledges624 that extend along each lateral side of the elongate slot 622. SeeFIG. 10. As the dynamic clamping assembly 550 is distally advanced, theanvil engagement tabs 557 slidably engage the anvil plate ledges 624 toretain the anvil assembly 612 clamped onto the target tissue. Similarly,during the firing operation, the body portion 552 of the dynamicclamping assembly 550 extends through a central slot in the channel 720and the channel engagement tabs 559 slidably engage channel ledges 725extending along each side of the central channel slot to retain thecartridge assembly 701 clamped onto the target tissue.

Turning to FIGS. 13 and 15, the channel 720 defines a docking areagenerally designated as 730 that is configured to accommodate thedynamic clamping assembly 550 when it is in its proximal most positionreferred to herein as an unfired or starting position. In particular,the docking area 730 is partially defined by planar docking surfaces 732that provides clearance between the channel engagement tabs 559 on thedynamic clamping assembly 550 to enable the cartridge assembly 701 topivot to a fully opened position. A ramped or camming surface 726extends from a distal end of each of the docking surfaces 732. Rampedsurface 726 is engaged by the dynamic clamping assembly 550 in order tomove the anvil assembly 612 and the cartridge assembly 701 with respectto one another. Similar camming surface could be provided on the anvilassembly 612 in other embodiments. It is envisioned that ramped surfaces726 may also facilitate the alignment and/or engagement between channel720 and support plate 620 and/or cartridge body 702. As the driveassembly 540 is distally advanced (fired), the channel engagement tabs559 on the dynamic clamping assembly 550 engage the corresponding rampedsurfaces 726 to apply a closing motion to the cartridge assembly 701thus closing the cartridge assembly 701 and the anvil assembly 612.Further distal translation of the dynamic clamping assembly 550 causesthe actuation sled 712 to move distally through cartridge body 702,which causes cam wedges 713 of actuation sled 712 to sequentially engagestaple pushers 709 to move staple pushers 709 vertically within stapleretention slots 706 and eject staples 704 into staple formingdepressions of anvil plate 620. Subsequent to the ejection of staples704 from retention slots 706 (and into tissue), the cutting edge 554 ofthe dynamic clamping assembly 550 severs the stapled tissue as thetissue cutting edge 554 on the vertical body portion 552 of the dynamicclamping assembly 550 travels distally through a central slot 703 ofcartridge body 702. After staples 704 have been ejected from cartridgebody 702 and a user wishes to use the same instrument 10 to fireadditional staples 704 (or another type of fastener or knife), the usercan remove the loading unit 510 from the adapter 200′ and replace itwith another fresh or unspent loading unit. In an alternativearrangement, the user may simply remove the spent cartridge body 702 andreplace it with a fresh unspent or unfired cartridge body 702.

During use of conventional adapters, debris and body fluids can migrateinto the outer tube of the adapter and detrimentally hamper theoperation of the adapter articulation and firing drive systems. Inegregious cases, such debris and fluids infiltrate into the innerhousing assembly of the adapter which may cause the electricalcomponents supported therein to short out and malfunction. Further, dueto limited access to the interior of the outer tube of the adapter, suchdebris and fluids are difficult to remove therefrom which can prevent orreduce the ability to reuse the adapter.

Turning to FIGS. 16 and 17, in one arrangement, at least one first seal230 is provided between the proximal inner housing assembly 204 and thefirst rotatable proximal drive shaft 212 to prevent fluid/debrisinfiltration within and proximal to the proximal inner housing assembly204. In addition, at least one second seal 232 is provided between thearticulation bar 258 and the outer tube 206 to prevent fluid/debris frompassing therebetween to enter the proximal inner housing assembly 204.At least one third housing seal 233 may be provided around a hub 205 ofthe proximal inner housing 204 to establish a seal between the hub 205and the outer knob housing 202. The first, second, and third seals 230,232, 233 may comprise, for example, flexible O-rings manufactured fromrubber or other suitable material.

In other arrangements, it may be desirable for the first and secondseals 230, 232 to be located in the adapter 200 distal to the electroniccomponents housed within the outer knob housing 202. For example, toprevent fluids/debris from fouling/shorting the slip ring assembly 298,it is desirable establish seals between the various moving components ofthe adapter 200 that are operably supported within the outer tube 206 ina location or locations that are each distal to the slip ring assembly298, for example. The seals 230, 232 may be supported in the wall of theouter tube and/or in mounting member 234 or other separate mountingmember/bushing/housing supported within the outer tube 206 andconfigured to facilitate axial movement of the distal drive member 248as well as the articulation bar 258 while establishing a fluid-tightseal between the bushing and/or outer tube and the distal drive member248 and the articulation bar 258. See FIGS. 18 and 20. In the embodimentillustrated in FIG. 19 for example, the first seal 230 may additionallyhave wiper features 231 that also slidably engage the distal drivemember 248 to prevent fluid/debris D from infiltrating in the proximaldirection PD into the proximal inner housing assembly 204. In at leastone arrangement to enable debris and fluids that have collected in theouter tube 206 distal to the first and second seals 230, 232, at leasttwo flushing ports 236, 238 are provided within the outer tube 206. Seee.g., FIGS. 18 and 20. The axially spaced flushing ports 236, 238 arelocated distal to the first and second seals 230, 232. A flushingsolution (e.g., cleaning fluid, saline fluid, air, etc.) may be enteredinto one or more port(s) to force the errant debris and fluid out of oneor more other port(s).

As discussed above, in one example, the surgical end effector 500comprises a loading unit 510 that is configured to be operably coupledto a distal end of a shaft assembly of an adapter. As can be seen inFIGS. 22-24, in one arrangement the loading unit 510 comprises aproximal body portion 520 and a tool assembly 600 that is configured tobe articulated relative to the proximal body portion 520. When theproximal body portion 520 is coupled to the shaft assembly, the proximalbody portion 520 is axially aligned with a longitudinal axis LA that isdefined by the shaft assembly of the adapter. When the tool assembly 600is in an unarticulated position (FIG. 22), an axis TA of the toolassembly 600 is aligned with the longitudinal axis LA of the adaptershaft assembly, for example. The tool assembly 600 may also bearticulated to a first side (FIG. 23) wherein the tool axis TA istransverse to the longitudinal axis LA as well as to a second side (FIG.24) wherein the tool axis TA is transverse to the longitudinal axis LA.During some articulation motions, an articulation bar 258 of the adaptermay encounter significant resistive forces. Sensing the resisting forceson the articulation frame or articulation bar 258 which isinterconnected to an articulation link 560 of the DLU or MLU via astrain gauge or other deflection oriented circuit would enable thecontrol circuit for the articulation motor to back drive thearticulation motor when the force exceeds a predetermined threshold.Such action would remove some or all of the resistance provided to thearticulation frame via the drive member of the adapter and therebyprevent internal drive damage and/or minimize collateral tissue damage.FIG. 26 illustrates use of multi-axis strain gauges 310, 312 on theouter tube assembly 206. The multi-axis strain gauges 310, 312 areconnected to the circuit board 294 located within the inner housingassembly 204 (shown in FIG. 6). The strain gauges may, in thealternative, be mounted on the articulation bar 258. In at least onearrangement, for example, the strain goes negative as the force on thearticulation bar 258 increases. Such arrangement may be particularlyuseful when the user intended to straighten the tool assembly (FIG. 22)to pull it back through a trocar, but failed to get the tool assembly600 fully straightened. In such case, the end effector may become jammedwithin the trocar cannula and/or result in high loading of thearticulation frame or articulation bar 258 and drive shaft 214. Thiscondition might be completely mitigated if the articulation system couldsense this condition via load on the articulation bar 258 or drive screw214 and longitudinally adjust the position of the articulation bar 258by energizing the articulation motor of the surgical instrument 100 towhich the adapter is attached until the bending forces are below thepredetermined threshold.

Articulation of the end effector 500 or, more particularly, thearticulation of the tool assembly 600 of the end effector 500 iscontrolled by rotating the second proximal drive shaft 214 that is inthreaded engagement with the articulation bearing assembly 252 as wasdiscussed above. See FIGS. 6-9. The second drive converting assembly 250of adapter 200 further includes articulation bar 258 that has a proximalportion that is secured to inner race 257 of articulation bearing 255.See FIG. 7. A distal portion of articulation bar 258 includes a slot 258a therein, which is configured to accept a hook 562 of the articulationlink 560 (FIG. 10) of end effector 500. Articulation bar 258 functionsas a force transmitting member to components of end effector 500. In theillustrated arrangement and as further discussed in WO 2016/057225 A1,articulation bearing assembly 252 is both rotatable and longitudinallytranslatable and is configured to permit free, unimpeded rotationalmovement of the tool assembly 600 of the end effector 500 when its jawmembers 610, 700 are in an approximated position and/or when jaw members610, 700 are articulated.

In operation, as second proximal drive shaft 214 is rotated due to arotation of second connector sleeve 222, as a result of the rotation ofthe second coupling shaft 64 c of surgical instrument 100, articulationbearing assembly 252 is translated axially along threaded distal endportion 214 a of second proximal drive shaft 214. This axial translationof the articulation bearing assembly 252 causes the articulation bar 258to be axially translated relative to outer tube 206. As articulation bar258 is translated axially, it causes concomitant axial translation ofarticulation link 560 of end effector 500 to effectuate an articulationof tool assembly 600. Articulation bar 258 is secured to inner race 257of articulation bearing 253 and is thus free to rotate about thelongitudinal axis relative to outer race 259 of articulation bearing253.

It may be desirable to control the articulation of the end effector andto monitor the articulated position thereof during a surgical procedure.FIGS. 27-29 illustrate an improved articulation control system or seconddrive converting assembly 3250. The second drive converting assembly3250 in many aspects is identical to the second drive convertingassembly 250 described above, except for the specific differencesdiscussed below. As can be seen in FIG. 27, the second drive convertingassembly 3250 includes second proximal drive shaft 3214 that isrotatably supported within inner housing assembly 204 (shown in FIG. 6).Second rotatable proximal drive shaft 3214 includes a non-circular orshaped proximal end portion 3215 that is configured for connection withsecond coupling shaft 64 c of surgical instrument 100. Second rotatableproximal drive shaft 3214 further includes a threaded distal end portion3214 a that is configured to threadably engage an articulation bearinghousing 3253 of an articulation bearing assembly 3252. Housing 3253supports an articulation bearing 255 that has an inner race 257 that isindependently rotatable relative to an outer race 259. Articulationbearing housing 3253 has a non-circular outer profile, for exampletear-dropped shaped, that is slidably and non-rotatably disposed withina complementary bore (not shown) of inner housing hub 204 a (FIG. 6).Second drive converting assembly 3250 further includes articulation bar3258 that has a proximal portion that is secured to inner race 257 ofarticulation bearing 255. A distal portion of articulation bar 3258includes a slot 3258 a therein, which is configured to accept a hook 562of the articulation link 560 (FIG. 10) of end effector 500. Articulationbar 3258 functions as a force transmitting member to components of endeffector 500.

In the illustrated arrangement, the articulation bearing housing 3253 isin threaded engagement with the threaded distal end portion 3214 a ofthe second rotatable proximal drive shaft 3214. The bearing housing 3253may also be referred to herein as an articulation driver arrangement. Inat least one example, the bearing housing or articulation driverarrangement 3252 is configured to move axially in two directions from acentral or neutral position (FIG. 27) to a proximal axial position (FIG.28) and to a distal axial position (FIG. 29). When the bearing housing3253 is in the central or neutral position, the tool assembly 600 isaxially aligned with the proximal body portion 520 such that the toolassembly axis TA is aligned with the longitudinal axis LA (FIG. 22).Stated another way, the tool assembly or surgical end effector isunarticulated. The tool assembly 600 is oriented in the unarticulatedposition initially to facilitate insertion of the end effector through atrocar cannula. When the second rotatable proximal drive shaft 3214 isrotated in a first rotary direction, the bearing housing 3252 is drivenin a proximal axial direction from the neutral position. As the bearinghousing 3252 moves in the proximal direction PD, the tool assembly 600articulates in a first articulation direction AD₁ until the bearinghousing 3252 reaches the proximal axial position (FIG. 28) at whichpoint the tool assembly 600 is fully articulated in the articulationdirection AD₁ shown in FIG. 23, for example. When the second rotatableproximal drive shaft 3214 is rotated in a second rotary direction(opposite the first rotary direction), the bearing housing 3253 isdriven in a distal direction DD from the neutral position. As thebearing housing 3253 moves in the distal direction DD, the tool assembly600 articulates in a second articulation direction AD₂ until the bearinghousing 3253 reaches the distal axial position (FIG. 29) at which pointthe tool assembly 600 is fully articulated in the articulation directionAD₂ shown in FIG. 24, for example.

As discussed above, to insert the surgical end effector into the patientthrough a cannula of a trocar, the tool assembly may need to be in theunarticulated position and it may need to be returned to theunarticulated position to enable the surgical end effector to be removedfrom the patient through the trocar cannula after the procedure iscompleted. Thus, the articulation control system may need to be able toprecisely control the axial position of the bearing housing to ensurethat the tool assembly is precisely aligned with the proximal housing toavoid possible jamming of the end effector with the trocar cannula. Inone example, an articulation sensor assembly, generally indicated as3300 is employed to communicate with a motor controller circuit board142 a (FIG. 4), or other controller arrangement of the electromechanicalsurgical instrument 100 to which the adapter is operably coupled. In theillustrated example, the articulation sensor assembly 3300 comprises aproximal sensor 3310 and a distal sensor 3320 that are mounted to asensor bracket 3302. In addition, the bearing housing 3253 includes asensor magnet 3330 as can be seen in FIG. 27. The proximal and distalsensors 3310, 3320 may comprise conventional Hall sensors and be wiredto the adapter circuit board 294 (FIG. 6) for ultimate electricalcommunication with the motor controller circuit board 142 a in theelectromechanical surgical instrument 100 (FIG. 4). The sensors 3310,3320 serve to detect the position of the sensor magnet 3330 so as tomonitor when the bearing housing 3253 nears the neutral position andreaches the neutral position and convey that information back to themotor controller circuit board. Such arrangement enables a motorcontroller algorithm to vary the speed of the articulation motor as itapproaches the neutral position to allow the user to stop near theneutral position without the system intentionally pausing at thatpredetermined position.

In addition to the above described articulation sensor assembly, anO-ring 3340 or similar feature is located on the threaded portion 3214 aof the second rotatable proximal drive shaft 3214 in place of or oversome of the threads of the threaded portion 3214 a. In such anarrangement, a spike in the articulation motor current (e.g., motor156—FIG. 4) will occur when the O-ring 3340 encounters a threadedportion 3350 of the bearing housing 3253. This current spike will occurwhen the O-ring 3340 encounters the threads 3350 to increase rotaryresistance or friction when entering from a proximal direction or adistal direction of travel and is used to determine the distance thatthe bearing housing 3253 is from the neutral position. Once a spike inmotor current is detected, an algorithm controlling the articulationmotor 156 sets the drive screw rotary position to zero and thearticulation motor 156 then rotates the drive screw 3214 in the properrotary direction to drive the bearing housing 3253 axially to reach theneutral position. In alternative arrangements of the O-ring, selectthreads of the threaded portion 3214 a may be removed or omitted orintentionally damaged or altered to alter the rotationalresistance/friction and thus alter the amount of motor current drawn bythe articulation motor to facilitate control of the articulation motorin the above-described manner.

FIGS. 30 and 31 depict an alternative proximal drive shaft 3414 that maybe employed to axially advance the bearing housing 3253 and detect theposition of the bearing housing 3253 as the drive shaft 3414 is rotatedin the first and second rotary directions. As can be seen in FIGS. 30and 31, the proximal drive shaft 3414 is formed with a proximal set ofthreads 3420, a distal set of threads 3430 and a center thread 3440. Thecenter thread 3440 is centrally located between the proximal set ofthreads 3420 and the distal set of threads 3430 and is separatedtherefrom by unthreaded portions 3450. Threads 3420, 3430, 3440 areconfigured to threadably engage internal threads 3350 formed in thebearing housing 3253. FIG. 30 illustrates the bearing housing 3253 inthe neutral position. As can be seen in FIG. 30, the least mount ofthreads (including the threads of the proximal thread segment 3420, thedistal thread segment 3430 and the center thread 3430) are in threadedcontact with the threads 3350 of the bearing housing 3253 and will thusresult in the lowest amount of current drawn by the articulation motor.FIG. 31 illustrates the bearing housing 3253 being moved in the proximaldirection with all of the threads of the proximal thread segment 3420 inthreaded engagement with the threads in the bearing housing 3253 whichwill cause the articulation motor 156 to experience a higher amount ofcurrent. Such higher current will also be experienced when the bearinghousing 3253 is driven in the distal direction DD. By monitoring whenthe current is at its lowest magnitude or is approaching the lowestmagnitude, an algorithm controlling the articulation motor 156 may beused to slow down and stop the articulation motor 156 in the variousmanners described herein.

FIGS. 32 and 33 depict an alternative proximal drive shaft 3514 andswitch arrangement 3550 that may be employed to detect when the bearinghousing 3253 approaches and reaches the neutral position as the driveshaft 3514 is rotated in the first and second rotary directions. As canbe seen in FIGS. 32 and 33, the proximal drive shaft 3514 is formed witha proximal set of threads 3520 and a distal set of threads 3530 that areseparated by an unthreaded central portion 3540 that has a diameter thatdecreases or tapers from each end so that it is smallest in its center.Threads 3520, 3530 are configured to threadably engage internal threads3350 formed in the bearing housing 3253. In this arrangement, the switcharrangement 3550 comprises a radially movable switch plunger 3552 thatis supported in the bearing housing 3253 and is biased into contact thedrive shaft 3514 by a biasing member such as a spring 3554. The switchplunger 3552 includes contacts 3556 that are configured to operablyinterface with contacts 3558 in the bearing housing 3253. FIG. 32illustrates the bearing housing 3253 in the neutral position. As can beseen in that FIG. 32, the switch plunger 3552 is in contact withapproximately the center of the unthreaded central portion 3540 of thedrive shaft 3514 such that the contacts 3556 are in contact with thecontacts 3558. Contacts 3556/3558 communicate with the motor controlcircuit in the surgical instrument 100 through the circuit board 294 toindicate that the bearing housing 3253 is in the neutral position. FIG.33 illustrates the bearing housing 3253 being moved in the proximaldirection PD with all of the threads of the proximal thread segment 3520in threaded engagement with the threads in the bearing housing 3253 andthe switch plunger 3552 in contact with the proximal thread segment 3520which moves the contacts 3556 away from contacts 3558 as shown. Thiscondition will also occur when the bearing housing 3253 is moved in thedistal direction. Such arrangements may be employed to control thearticulation motor in the above-described manners.

FIGS. 34-37 depict an alternative switch arrangement 3650 for detectingwhen the bearing housing 3553 is in the neutral position. In thisarrangement for example, the switch arrangement 3650 is supported in theinner housing 204 and includes a radially movable switch plunger 3652.As can be seen in FIGS. 34-37, the bearing housing 3553 is formed withan activator detent 3555 that is configured to interact with the switchplunger 3652. The switch plunger 3652 interacts with a leaf spring 3654that is configured to engage a contact 3658 in the inner housing 204.FIG. 35 illustrates the bearing housing 3553 in a neutral position. Whenin that position, the switch plunger 3652 has biased the leaf spring3654 into contact with the contact 3658 to complete a circuit to informthe motor controller circuit through the circuit board 294 that thebearing housing 3553 is in the neutral position. FIG. 36 illustrates thebearing housing 3553 in a position that is proximal to the neutralposition such that the detent 3555 on the bearing housing 3553 isproximal to the center of the switch plunger 3652 to enable the spring3654 to move out of contact with the contact 3658. FIG. 37 illustratesthe bearing housing 3553 in a position distal to the neutral positionsuch that the detent 3555 on the bearing housing 3553 is distal to thecenter of the switch plunger 3652 to enable the leaf spring 3654 to moveout of contact with the contact 3658. Such arrangements may be employedto control the articulation motor 158 in the above-described manners.

As described above, in at least some examples, the adapter 200 employs aproximal rotary drive shaft 216 that is ultimately rotated by acorresponding motor in the surgical instrument 100 to rotate the shaftassembly about the longitudinal axis LA. During a procedure, it may bedesirable for the clinician to know the exact rotary position of theshaft assembly for adjustment purposes and resetting purposes. Onearrangement, for example, could employ an optical detector arrangementfor detecting incremental etched or printed markings on the outer shafttube 206, for example. Such markings may be provided completely around aproximal end portion of the outer tube 206 that allow for detection andindication of multiple 360 increments. Longitudinal marks may correlatewith a ring advancing feature that moves one increment distal for eachfull 360° rotation.

FIG. 38 illustrates another rotational detection system 3750 that may beemployed to detect and control the rotation of the shaft assembly aboutthe longitudinal axis LA. As can be seen in that Figure, the rotationaldetection system 3750 includes a pair of rotational sensors 3752, 3754that are configured to sense the position of a sensor magnet 3756 in oneof the opposed, radially extending protrusions 266 b. The sensors 3752,3754 are below the centerline of the adapter. In another arrangement,one rotational sensor is employed and a sensor magnet is mounted in eachof the protrusions 266 b. The magnets are oriented so their polaritiesare different. Due to the different polarities, a single sensor is ableto detect the positions of both magnets ensuring unique tracking of eachmagnet and proper determination of position. This information istransmitted to the motor controller circuit in the surgical instrument100 through circuit board 294 and contacts 292. A control algorithm maybe employed to control the second motor 154 such that the rotation ofthe shaft assembly may be limited to rotate through a certain range orstop at a certain point or to bring the rotations induced within thelast use back to a zero position. In other examples, multiple 360°rotation overall limiting features which allow the shaft to turn apredetermined number of 360° rotations before instructing the user tocounter rotate. In other arrangements, the system may automaticallycause the motor to counter rotate the shaft assembly after the firstclosure cycle after the cartridge is reloaded or the DLU is replaced.

EXAMPLES Example 1

An adapter for use with an electromechanical surgical instrument. In atleast one example, the adapter comprises an adapter housing assemblythat is configured to be operably coupled to the electromechanicalsurgical instrument. A shaft assembly defines a longitudinal axis thatextends between a proximal end and a distal end thereof. The proximalend is operably coupled to the adapter housing assembly. A surgical endeffector is operably coupled to the distal end of the shaft assembly forselective articulation relative to the shaft assembly. The adapterfurther comprises an articulation control system that includes a rotarydrive shaft that is configured to operably interface with a source ofrotary drive motions in the electromechanical surgical instrument whenthe adapter housing assembly is operably coupled thereto. Anarticulation driver arrangement operably interfaces with the rotarydrive shaft and the surgical end effector. The articulation driverarrangement comprises an articulation member that is configured to moveaxially in response to rotation of the rotary drive shaft to articulatethe surgical end effector through a range of articulated orientations.The articulation control system further comprises means for monitoringan axial position of the articulation member during rotation of therotary drive member. The means is also configured to communicate asignal corresponding to the axial position of the articulation member tothe electromechanical surgical instrument when the adapter housingassembly is operably coupled thereto.

Example 2

The adapter of Example 1, wherein the articulation member is configuredto move axially between a beginning axial position and an ending axialposition in response to rotation of the rotary drive shaft. The meansfor monitoring is configured to monitor the axial position of thearticulation member between the beginning axial position and the endingaxial position.

Example 3

The adapter of Example 2, wherein the means for monitoring comprises anarticulation sensor assembly that is configured to communicate with theelectromechanical surgical instrument when the adapter housing assemblyis operably coupled thereto. In at least one example, the articulationsensor assembly comprises a first articulation sensor that correspondsto the beginning axial position and a second articulation sensor thatcorresponds to the ending axial position. The first and secondarticulation sensors are configured to detect the axial position of thearticulation member between the beginning axial position and the endingaxial position and generate the signal that corresponds to the axialposition of the articulation member and communicate the signal to theelectromechanical surgical instrument.

Example 4

The adapter of Example 3, wherein a portion of the articulation memberis operably supported in an axially movable articulation bearing housingthat is in threaded engagement with the rotary drive shaft and isconfigured to move between the beginning axial position and the endingaxial position in response to rotation of the rotary drive shaft. Thefirst and second articulation sensors are configured to sense a positionof an articulation magnet that is supported by the articulation bearinghousing.

Example 5

The adapter of Examples 2, 3 or 4, wherein when a portion of thearticulation member is in a neutral axial position located between thebeginning axial position and the ending axial position, the surgical endeffector is axially aligned with the longitudinal axis in anunarticulated position.

Example 6

The adapter of Example 5, further comprising means for determining whenthe portion of the articulation member is in the neutral axial position.

Example 7

The adapter of Example 6, wherein the portion of the articulation memberis operably supported in an axially movable articulation bearing housingthat is in threaded engagement with the rotary drive shaft and isconfigured to move between the beginning axial position and the endingaxial position in response to rotation of the rotary drive shaft. Themeans for determining when the portion of the articulation member is inthe neutral axial position comprises a neutral switch member that isconfigured to detect the bearing housing when the bearing housing is inthe neutral axial position and send a corresponding signal to theelectromechanical instrument.

Example 8

The adapter of Examples 6 or 7, wherein the source of rotary drivemotions comprises an electrical powered articulation motor in theelectromechanical surgical instrument. The rotary drive shaft isconfigured to operably interface with an output shaft of theelectrically powered articulation motor such that operation of theelectrical powered articulation motor at a an electrical current levelis sufficient to move the portion of the articulation member between thebeginning axial position and the ending axial position. The means fordetermining when the portion of the articulation member is in theneutral axial position comprises means for altering the level ofelectrical current when the portion of the articulation member is in theneutral position.

Example 9

The adapter of Example 8, wherein the portion of the articulation memberis operably supported in an axially movable articulation bearing housingthat is in threaded engagement with a threaded portion of the rotarydrive shaft and is configured to move between the beginning axialposition and the ending axial position in response to rotation of therotary drive shaft. The means for altering the level of electricalcurrent when the portion of the articulation member is in the neutralposition comprises a rotational resistance generator on the rotary driveshaft that is configured to increase rotational resistance between therotary drive shaft and the articulation bearing housing when thearticulation bearing housing is in the neutral position to therebyincrease the level of electrical current drawn by the electrical poweredarticulation motor.

Example 10

The adapter of Example 9, wherein the rotational resistance generatorcomprises an O-ring on the threaded portion of the rotary drive shaft.

Example 11

The adapter of Example 6, wherein the portion of the articulation memberis operably supported in an axially movable articulation bearing housingthat is in threaded engagement with the rotary drive shaft and isconfigured to move between the beginning axial position and the endingaxial position in response to rotation of the rotary drive shaft. Thesource of rotary drive motions comprises an electrical poweredarticulation motor in the electromechanical surgical instrument. Therotary drive shaft is configured to operably interface with an outputshaft of the electrically powered articulation motor such that when theelectrical powered articulation motor draws a level of electricalcurrent, the articulation motor causes the rotary drive shaft to movesaid portion of said articulation member between the beginning axialposition and the ending axial position. The means for determining whenthe portion of the articulation member is in the neutral axial positioncomprises a thread arrangement on the rotary drive shaft that isconfigured to reduce the level of electrical current drawn by theelectrically powered articulation motor when the bearing housing is inthe neutral axial position.

Example 12

The adapter of Example 11, wherein the thread arrangement comprises aplurality of threads in threaded engagement with the bearing housing formoving the bearing housing between said beginning and ending axialpositions. The plurality of threads are configured such that a lessernumber of threads are in threaded engagement with the bearing housingwhen the bearing housing is in the neutral position so as to reduce thelevel of electrical current drawn by the electrically poweredarticulation motor.

Example 13

The adapter of Example 6, wherein the portion of the articulation memberis operably supported in an axially movable articulation housing that isin threaded engagement with a thread arrangement of the rotary driveshaft and is configured to move between the beginning axial position andthe ending axial position in response to rotation of the rotary driveshaft. The thread arrangement comprises a first thread segment that isconfigured to threadably engage the articulation housing and a secondthread segment that is spaced from the first thread segment by a centralsegment that has a configuration that differs from the first and secondthread segments. The means for determining when the portion of thearticulation member is in the neutral axial position comprises a sensorassembly that is configured to interact with the central segment andgenerate a signal that is indicative of an axial position of the movablearticulation housing.

Example 14

The adapter of Example 13, wherein the central segment is not threaded.

Example 15

The adapter of Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13 or 14,wherein the adapter housing assembly comprises a drive coupler portionthat is configured to be operably coupled to the electromechanicalsurgical instrument. An outer knob housing is coupled to the shaftassembly and is rotatably supported on the drive coupler portion forselective rotation relative thereto about the longitudinal axis. Theadapter further comprises a rotary drive system that is configured tooperably interface with another source of rotary drive motions in theelectromechanical surgical instrument when the drive coupler portion isoperably coupled thereto. The rotary drive system is configured toselectively rotate the outer knob housing about the longitudinal axis.The adapter further comprises means for monitoring a rotary position ofthe outer knob housing during operation of the rotary drive system andcommunicating another signal corresponding to the rotary position of theouter knob housing to the electromechanical surgical instrument when thedrive coupler portion is operably coupled thereto.

Example 16

The adapter of Example 15, wherein the rotary drive system comprisesanother rotary drive shaft arrangement that is configured to operablyinterface with another source of rotary drive motions in theelectromechanical surgical instrument. The other rotary drive shaftarrangement is in meshing engagement with the outer knob housing suchthat rotation of the other rotary drive shaft rotates the outer knobhousing. The means for monitoring a rotary position of the outer knobhousing comprises a sensor arrangement that is configured to detect atleast one magnet that is supported by the outer knob housing.

Example 17

An adapter for use with an electromechanical surgical instrument. In atleast one example, the adapter comprises a shaft assembly that defines alongitudinal axis that extends between a proximal end and a distal endthereof. A surgical end effector is operably coupled to the distal endof the shaft assembly. The adapter further comprises an adapter housingassembly that includes a drive coupler portion that is configured to beoperably coupled to the electromechanical surgical instrument. An outerknob housing is coupled to the shaft assembly and is rotatably supportedon the drive coupler portion for selective rotation relative theretoabout the longitudinal axis. The adapter further comprises a rotarydrive system that is configured to operably interface with a source ofrotary drive motions in the electromechanical surgical instrument whenthe drive coupler portion is operably coupled thereto. The rotary drivesystem is configured to selectively rotate the outer knob housing aboutthe longitudinal axis. The adapter also comprises means for monitoring arotary position of the outer knob housing about the longitudinal axisduring operation of the rotary drive system and communicating a signalcorresponding to the rotary position to the electromechanical surgicalinstrument.

Example 18

The adapter of Example 17, wherein the rotary drive system comprises arotary drive shaft arrangement that is configured to operably interfacewith the source of rotary drive motions in the electromechanicalsurgical instrument. The rotary drive shaft arrangement is in meshingengagement with the outer knob housing such that rotation of the rotarydrive shaft rotates the outer knob housing. The means for monitoring arotary position of the outer knob housing comprises a sensor arrangementthat is configured to detect at least one magnet that is supported bythe outer knob housing.

Example 19

An adapter for use with an electromechanical surgical instrument. In atleast one example, the adapter comprises an adapter housing assemblythat is configured to be operably coupled to the electromechanicalsurgical instrument. A shaft assembly defines a longitudinal axis thatextends between a proximal end and a distal end thereof. The proximalend is operably coupled to the adapter housing assembly. A surgicalloading unit is operably coupled to the distal end of the shaft assemblyfor selective articulation relative to the shaft assembly. The surgicalloading unit comprises a staple cartridge assembly and an anvilassembly. A dynamic clamping assembly is axially movable in the surgicalloading unit in response to a firing drive motion applied thereto toclamp the anvil assembly and staple cartridge assembly onto tissue andcut the clamped tissue and fire staples from the staple cartridgeassembly. The adapter further comprises a first rotary drive shaftassembly that is configured to operably interface with a first source ofrotary drive motions in the electromechanical surgical instrument andthe dynamic clamping assembly to apply the firing drive motion thereto.The adapter further comprises an articulation control system thatincludes a second rotary drive shaft that is configured to operablyinterface with a second source of rotary drive motions in theelectromechanical surgical instrument when the adapter housing assemblyis operably coupled thereto. An articulation driver arrangement operablyinterfaces with the second rotary drive shaft and the surgical loadingunit and comprises an articulation member that is configured to moveaxially in response to rotation of the second rotary drive shaft toarticulate the surgical loading unit through a range of articulatedorientations. The adapter further comprises means for monitoring anaxial position of the articulation member during rotation of the secondrotary drive member and communicating a signal corresponding to theaxial position to the electromechanical surgical instrument when theadapter housing is operably coupled thereto.

Example 20

The adapter of Example 19, wherein the adapter housing comprises a drivecoupler portion that is configured to be operably coupled to theelectromechanical surgical instrument. An outer knob housing is coupledto the shaft assembly and is rotatably supported on the drive couplerportion for selective rotation relative thereto about the longitudinalaxis. The adapter further comprises a rotary drive system that isconfigured to operably interface with a third source of rotary drivemotions in the electromechanical surgical instrument when the drivecoupler portion is operably coupled thereto and is configured toselectively rotate the outer knob housing about the longitudinal axis.The adapter further comprised means for monitoring a rotary position ofthe outer knob housing during operation of the rotary drive system andcommunicating another signal corresponding to the rotary position to theelectromechanical surgical instrument when the drive coupler portion isoperably coupled thereto.

Many of the surgical instrument systems described herein are motivatedby an electric motor; however, the surgical instrument systems describedherein can be motivated in any suitable manner. In various instances,the surgical instrument systems described herein can be motivated by amanually-operated trigger, for example. In certain instances, the motorsdisclosed herein may comprise a portion or portions of a roboticallycontrolled system. Moreover, any of the end effectors and/or toolassemblies disclosed herein can be utilized with a robotic surgicalinstrument system. U.S. patent application Ser. No. 13/118,241, entitledSURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, disclosesseveral examples of a robotic surgical instrument system in greaterdetail.

The surgical instrument systems described herein have been described inconnection with the deployment and deformation of staples; however, theembodiments described herein are not so limited. Various embodiments areenvisioned which deploy fasteners other than staples, such as clamps ortacks, for example. Moreover, various embodiments are envisioned whichutilize any suitable means for sealing tissue. For instance, an endeffector in accordance with various embodiments can comprise electrodesconfigured to heat and seal the tissue. Also, for instance, an endeffector in accordance with certain embodiments can apply vibrationalenergy to seal the tissue.

Although various devices have been described herein in connection withcertain embodiments, modifications and variations to those embodimentsmay be implemented. Particular features, structures, or characteristicsmay be combined in any suitable manner in one or more embodiments. Thus,the particular features, structures, or characteristics illustrated ordescribed in connection with one embodiment may be combined in whole orin part, with the features, structures or characteristics of one oremore other embodiments without limitation. Also, where materials aredisclosed for certain components, other materials may be used.Furthermore, according to various embodiments, a single component may bereplaced by multiple components, and multiple components may be replacedby a single component, to perform a given function or functions. Theforegoing description and following claims are intended to cover allsuch modification and variations.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, a device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the stepsincluding, but not limited to, the disassembly of the device, followedby cleaning or replacement of particular pieces of the device, andsubsequent reassembly of the device. In particular, a reconditioningfacility and/or surgical team can disassemble a device and, aftercleaning and/or replacing particular parts of the device, the device canbe reassembled for subsequent use. Those skilled in the art willappreciate that reconditioning of a device can utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

The devices disclosed herein may be processed before surgery. First, anew or used instrument may be obtained and, when necessary, cleaned. Theinstrument may then be sterilized. In one sterilization technique, theinstrument is placed in a closed and sealed container, such as a plasticor TYVEK bag. The container and instrument may then be placed in a fieldof radiation that can penetrate the container, such as gamma radiation,x-rays, and/or high-energy electrons. The radiation may kill bacteria onthe instrument and in the container. The sterilized instrument may thenbe stored in the sterile container. The sealed container may keep theinstrument sterile until it is opened in a medical facility. A devicemay also be sterilized using any other technique known in the art,including but not limited to beta radiation, gamma radiation, ethyleneoxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

What is claimed is:
 1. An adapter for use with an electromechanicalsurgical instrument, said adapter comprising: an adapter housingassembly configured to be operably coupled to the electromechanicalsurgical instrument; a shaft assembly defining a longitudinal axisbetween a proximal end and a distal end thereof, said proximal endoperably coupled to said adapter housing assembly; a surgical endeffector operably coupled to said distal end of said shaft assembly forselective articulation relative to said shaft assembly; and anarticulation control system, comprising: a rotary drive shaft configuredto operably interface with a source of rotary drive motions in theelectromechanical surgical instrument when said adapter housing assemblyis operably coupled thereto; an articulation driver arrangement operablyinterfacing with said rotary drive shaft at a point of interface withinsaid shaft assembly, wherein said articulation driver arrangementfurther operably interfaces with said surgical end effector, whereinsaid articulation driver arrangement comprises an articulation memberconfigured to move axially in response to rotation of said rotary driveshaft to articulate said surgical end effector through a range ofarticulated orientations; and means for monitoring an axial position ofsaid articulation member during rotation of said rotary drive shaft,wherein said means for monitoring is located at said point of interfaceand is configured to communicate a signal corresponding to said axialposition to the electromechanical surgical instrument when said adapterhousing assembly is operably coupled thereto.
 2. The adapter of claim 1,wherein said articulation member is configured to move axially between abeginning axial position and an ending axial position in response torotation of said rotary drive shaft and wherein said means formonitoring is configured to monitor said axial position of saidarticulation member between said beginning axial position and saidending axial position.
 3. The adapter of claim 2, wherein said means formonitoring comprises an articulation sensor assembly configured tocommunicate with the electromechanical surgical instrument when saidadapter housing assembly is operably coupled thereto, wherein saidarticulation sensor assembly comprises: a first articulation sensorcorresponding to said beginning axial position; and a secondarticulation sensor corresponding to said ending axial position, whereinsaid first articulation sensor and said second articulation sensor areconfigured to detect said axial position of said articulation memberbetween said beginning axial position and said ending axial position andgenerate said signal corresponding to said axial position of saidarticulation member and communicate said signal to the electromechanicalsurgical instrument.
 4. The adapter of claim 3, wherein a portion ofsaid articulation member is operably supported in an axially movablearticulation bearing housing that is in threaded engagement with saidrotary drive shaft, wherein said axially movable articulation bearinghousing is configured to move between said beginning axial position andsaid ending axial position in response to rotation of said rotary driveshaft and wherein said first articulation sensor and said secondarticulation sensor are configured to sense a position of anarticulation magnet supported by said axially movable articulationbearing housing.
 5. The adapter of claim 2, wherein when a portion ofsaid articulation member is in a neutral axial position located betweensaid beginning axial position and said ending axial position, saidsurgical end effector is axially aligned with said longitudinal axis inan unarticulated position.
 6. The adapter of claim 5, further comprisingmeans for determining when said portion of said articulation member isin said neutral axial position.
 7. The adapter of claim 6, wherein saidportion of said articulation member is operably supported in an axiallymovable articulation bearing housing that is in threaded engagement withsaid rotary drive shaft, wherein said axially movable articulationbearing housing is configured to move between said beginning axialposition and said ending axial position in response to rotation of saidrotary drive shaft and wherein said means for determining when saidportion of said articulation member is in said neutral axial positioncomprises a neutral switch member configured to detect said axiallymovable articulation bearing housing when said axially movablearticulation bearing housing is in said neutral axial position and senda corresponding signal to the electromechanical instrument.
 8. Theadapter of claim 7, wherein the source of rotary drive motions comprisesan electrically powered articulation motor in the electromechanicalsurgical instrument and wherein said rotary drive shaft is configured tooperably interface with an output shaft of the electrically poweredarticulation motor such that operation of the electrically poweredarticulation motor at a an electrical current level to move said portionof said articulation member between said beginning axial position andsaid ending axial position, and wherein said means for determining whensaid portion of said articulation member is in said neutral axialposition comprises means for altering said level of electrical currentwhen said portion of said articulation member is in said neutralposition.
 9. The adapter of claim 8, wherein said means for alteringsaid level of electrical current when said portion of said articulationmember is in said neutral position comprises a rotational resistancegenerator on said rotary drive shaft, wherein said rotational resistancegenerator is configured to increase rotational resistance between saidrotary drive shaft and said articulation bearing housing when saidarticulation bearing housing is in said neutral position to therebyincrease said level of electrical current drawn by the electricallypowered articulation motor.
 10. The adapter of claim 9, wherein saidrotational resistance generator comprises an O-ring on said threadedportion of said rotary drive shaft.
 11. The adapter of claim 6, whereinsaid portion of said articulation member is operably supported in anaxially movable articulation bearing housing that is in threadedengagement with said rotary drive shaft, wherein said axially movablearticulation bearing housing is and is configured to move between saidbeginning axial position and said ending axial position in response torotation of said rotary drive shaft and wherein the source of rotarydrive motions comprises an electrically powered articulation motor inthe electromechanical surgical instrument and wherein said rotary driveshaft is configured to operably interface with an output shaft of theelectrically powered articulation motor such that when the electricallypowered articulation motor draws a level of electrical current, theelectrically powered articulation motor causes said rotary drive shaftto move said portion of said articulation member between said beginningaxial position and said ending axial position and wherein said means fordetermining when said portion of said articulation member is in saidneutral axial position comprises a thread arrangement on said rotarydrive shaft that is configured to reduce the level of electrical currentdrawn by the electrically powered articulation motor when said axiallymovable articulation bearing housing is in said neutral axial position.12. The adapter of claim 11, wherein said thread arrangement comprises aplurality of threads in threaded engagement with said axially movablearticulation bearing housing to move said axially movable articulationbearing housing between said beginning axial position and said endingaxial position, and wherein said plurality of threads is configured suchthat a lesser number of said plurality of threads are in threadedengagement with said axially movable articulation bearing housing whensaid axially movable articulation bearing housing is in said neutralposition so as to reduce the level of electrical current drawn by theelectrically powered articulation motor.
 13. The adapter of claim 6,wherein said portion of said articulation member is operably supportedin an axially movable articulation bearing housing that is in threadedengagement with a thread arrangement of said rotary drive shaft and isconfigured to move between said beginning axial position and said endingaxial position in response to rotation of said rotary drive shaft,wherein said thread arrangement comprises: a first thread segmentconfigured to threadably engage said axially movable articulationbearing housing; and a second thread segment spaced from said firstthread segment by a central segment, wherein said central segmentcomprises a configuration that differs from said first thread segmentand said second thread segment, and wherein said means for determiningwhen said portion of said articulation member is in said neutral axialposition comprises a sensor assembly configured to interact with saidcentral segment and generate a signal indicative of an axial position ofsaid axially movable articulation bearing housing.
 14. The adapter ofclaim 13, wherein said central segment is not threaded.
 15. The adapterof claim 1, wherein said adapter housing assembly comprises: a drivecoupler portion configured to be operably coupled to theelectromechanical surgical instrument; and an outer knob housing coupledto said shaft assembly and rotatably supported on said drive couplerportion for selective rotation relative thereto about said longitudinalaxis and wherein said adapter further comprises: a rotary drive systemconfigured to operably interface with another source of rotary drivemotions in the electromechanical surgical instrument when said drivecoupler portion is operably coupled thereto, said rotary drive systemconfigured to selectively rotate said outer knob housing about saidlongitudinal axis; and means for monitoring a rotary position of saidouter knob housing during operation of said rotary drive system andcommunicating another signal corresponding to said rotary position tothe electromechanical surgical instrument when said drive couplerportion is operably coupled thereto.
 16. The adapter of claim 15,wherein said rotary drive system comprises another rotary drive shaftarrangement configured to operably interface with the another source ofrotary drive motions in the electromechanical surgical instrument, saidanother rotary drive shaft arrangement in meshing engagement with saidouter knob housing such that rotation of said another rotary drive shaftrotates said outer knob housing and wherein said means for monitoring arotary position of said outer knob housing comprises a sensorarrangement configured to detect at least one magnet supported by saidouter knob housing.
 17. An adapter for use with an electromechanicalsurgical instrument, said adapter comprising: a shaft assembly defininga longitudinal axis between a proximal end and a distal end thereof; asurgical end effector operably coupled to said distal end of said shaftassembly; an adapter housing assembly comprising: a drive couplerportion configured to be operably coupled to the electromechanicalsurgical instrument; and an outer knob housing coupled to said shaftassembly and rotatably supported on said drive coupler portion forselective rotation relative thereto about said longitudinal axis andwherein said adapter further comprises: a rotary drive system configuredto operably interface with a source of rotary drive motions in theelectromechanical surgical instrument when said drive coupler portion isoperably coupled thereto, and wherein when the source of rotary motionsin the electromechanical surgical instrument is actuated, said rotarydrive system selectively rotates said outer knob housing about saidlongitudinal axis; and means for monitoring a rotary position of saidouter knob housing about said longitudinal axis during operation of saidrotary drive system and communicating a signal corresponding to saidrotary position to the electromechanical surgical instrument.
 18. Theadapter of claim 17, wherein said rotary drive system comprises a rotarydrive shaft arrangement configured to operably interface with the sourceof rotary drive motions in the electromechanical surgical instrument,said rotary drive shaft arrangement in meshing engagement with saidouter knob housing such that rotation of said rotary drive shaftarrangement rotates said outer knob housing and wherein said means formonitoring a rotary position of said outer knob housing comprises asensor arrangement configured to detect at least one magnet supported bysaid outer knob housing.
 19. An adapter for use with anelectromechanical surgical instrument, said adapter comprising: anadapter housing assembly configured to be operably coupled to theelectromechanical surgical instrument; a shaft assembly defining alongitudinal axis between a proximal end and a distal end thereof, saidproximal end operably coupled to said adapter housing assembly; asurgical loading unit operably coupled to said distal end of said shaftassembly for selective articulation relative to said shaft assembly,said surgical loading unit comprising: a staple cartridge assembly; ananvil assembly; and a dynamic clamping assembly axially movable in saidsurgical loading unit in response to a firing drive motion appliedthereto to clamp said anvil assembly and staple cartridge assembly ontotissue and cut the clamped tissue and fire staples from the staplecartridge assembly and wherein said adapter further comprises: a firstrotary drive shaft assembly configured to operably interface with afirst source of rotary drive motions in the electromechanical surgicalinstrument and said dynamic clamping assembly to apply said firing drivemotion thereto; and an articulation control system, comprising: a secondrotary drive shaft configured to operably interface with a second sourceof rotary drive motions in the electromechanical surgical instrumentwhen said adapter housing assembly is operably coupled thereto; anarticulation driver arrangement operably interfacing with said secondrotary drive shaft and said surgical loading unit and comprising anarticulation member configured to move axially in response to rotationof said second rotary drive shaft to articulate said surgical loadingunit through a range of articulated orientations; and means formonitoring an axial position of said articulation member during rotationof said second rotary drive shaft and communicating a signalcorresponding to said axial position to the electromechanical surgicalinstrument when said adapter housing is operably coupled thereto. 20.The adapter of claim 19, wherein said adapter housing comprises: a drivecoupler portion configured to be operably coupled to theelectromechanical surgical instrument; and an outer knob housing coupledto said shaft assembly and rotatably supported on said drive couplerportion for selective rotation relative thereto about said longitudinalaxis and wherein said adapter further comprises: a rotary drive systemconfigured to operably interface with a third source of rotary drivemotions in the electromechanical surgical instrument when said drivecoupler portion is operably coupled thereto and configured toselectively rotate said outer knob housing about said longitudinal axis;and means for monitoring a rotary position of said outer knob housingduring operation of said rotary drive system and communicating anothersignal corresponding to said rotary position to the electromechanicalsurgical instrument when said drive coupler portion is operably coupledthereto.
 21. An adapter for use with an electromechanical surgicalinstrument, wherein the electromechanical instrument comprises anelectrically powered articulation motor, and wherein said adaptercomprises: an adapter housing assembly configured to be operably coupledto the electromechanical surgical instrument; a shaft assembly defininga longitudinal axis between a proximal end and a distal end thereof,said proximal end operably coupled to said adapter housing assembly; asurgical end effector operably coupled to said distal end of said shaftassembly for selective articulation relative to said shaft assembly; andan articulation control system, comprising: a rotary drive shaftconfigured to operably interface with the electrically poweredarticulation motor when said adapter housing assembly is operablycoupled to the electromechanical instrument; an articulation driverarrangement operably interfacing with said rotary drive shaft and saidsurgical end effector and comprising an articulation member configuredto move axially in response to rotation of said rotary drive shaft toarticulate said surgical end effector through a range of articulatedorientations, wherein a portion of said articulation member is operablysupported in an axially movable articulation bearing housing that is inthreaded engagement with said rotary drive shaft and is configured tomove between a beginning axial position, an ending axial position, and aneutral axial position located between said beginning axial position andsaid ending axial position in response to rotation of said rotary driveshaft, wherein when said portion of said articulation member is in saidneutral axial position, said surgical end effector is axially alignedwith said longitudinal axis in an unarticulated position, and whereinwhen the electrically powered articulation motor draws a level ofelectrical current, said rotary drive shaft moves said portion of saidarticulation member between said beginning axial position and saidending axial position; a thread arrangement on said rotary drive shaftthat is configured to reduce the level of electrical current drawn bythe electrically powered articulation motor when said axially movablearticulation bearing housing is in said neutral axial position; andmeans for monitoring an axial position of said articulation memberbetween said beginning axial position and said ending axial positionduring rotation of said rotary drive member and communicating a signalcorresponding to said axial position to the electromechanical surgicalinstrument when said adapter housing assembly is operably coupledthereto.
 22. The adapter of claim 21, wherein said means for monitoringcomprises an articulation sensor assembly configured to communicate withthe electromechanical surgical instrument when said adapter housingassembly is operably coupled thereto, said articulation sensor assemblycomprising: a first articulation sensor corresponding to said beginningaxial position; and a second articulation sensor corresponding to saidending axial position, wherein said first articulation sensor and secondarticulation sensor are configured to detect said axial position of saidarticulation member between said beginning axial position and saidending axial position and generate said signal corresponding to saidaxial position of said articulation member and communicate said signalto the electromechanical surgical instrument.
 23. The adapter of claim22, further comprises a neutral switch member configured to detect saidaxially movable articulation bearing housing when said axially movablearticulation bearing housing is in said neutral axial position and senda corresponding signal to the electromechanical instrument.
 24. Theadapter of claim 23, comprises means for altering said level ofelectrical current when said portion of said articulation member is insaid neutral position.
 25. The adapter of claim 24, wherein said meansfor altering said level of electrical current when said portion of saidarticulation member is in said neutral position comprises a rotationalresistance generator on said rotary drive shaft configured to increaserotational resistance between said rotary drive shaft and said axiallymovable articulation bearing housing when said axially movablearticulation bearing housing is in said neutral position to therebyincrease said level of electrical current drawn by the electricallypowered articulation motor.
 26. The adapter of claim 25, wherein saidrotational resistance generator comprises an O-ring on said threadedportion of said rotary drive shaft.
 27. The adapter of claim 21, whereinsaid thread arrangement comprises a plurality of threads in threadedengagement with said axially movable articulation bearing housing tomove said axially movable articulation bearing housing between saidbeginning axial position and said ending axial position and configuredsuch that a lesser number of said plurality of threads are in threadedengagement with said axially movable articulation bearing housing whensaid axially movable articulation bearing housing is in said neutralposition so as to reduce the level of electrical current drawn by theelectrically powered articulation motor.
 28. The adapter of claim 21,wherein said thread arrangement comprises: a first thread segmentconfigured to threadably engage said axially movable articulationbearing housing; and a second thread segment spaced from said firstthread segment by a central segment having a configuration that differsfrom said first and second thread segments and wherein said means fordetermining when said portion of said articulation member is in saidneutral axial position comprises a sensor assembly configured tointeract with said central segment and generate a signal indicative ofan axial position of said axially movable articulation bearing housing.29. The adapter of claim 28, wherein said central segment is notthreaded.
 30. The adapter of claim 21, wherein said adapter housingassembly comprises: a drive coupler portion configured to be operablycoupled to the electromechanical surgical instrument; and an outer knobhousing coupled to said shaft assembly and rotatably supported on saiddrive coupler portion for selective rotation relative thereto about saidlongitudinal axis and wherein said adapter further comprises: a rotarydrive system configured to operably interface with another source ofrotary drive motions in the electromechanical surgical instrument whensaid drive coupler portion is operably coupled thereto, said rotarydrive system configured to selectively rotate said outer knob housingabout said longitudinal axis; and means for monitoring a rotary positionof said outer knob housing during operation of said rotary drive systemand communicating another signal corresponding to said rotary positionto the electromechanical surgical instrument when said drive couplerportion is operably coupled thereto.
 31. The adapter of claim 30,wherein said rotary drive system comprises another rotary drive shaftarrangement configured to operably interface with the another source ofrotary drive motions in the electromechanical surgical instrument, saidanother rotary drive shaft arrangement in meshing engagement with saidouter knob housing such that rotation of said another rotary drive shaftrotates said outer knob housing and wherein said means for monitoring arotary position of said outer knob housing comprises a sensorarrangement configured to detect at least one magnet supported by saidouter knob housing.